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Ariel Corporation

ER- Instrumentation
56.07

Packagers must provide safety shutdowns, controls, and instrumentation to ensure the compressor system operates within published Ariel limits. The use of
“alarm” instead of “shutdown” for any minimum instrumentation requirement may result in equipment damage. Additional information for control and
instrumentation may be found in the appropriate Ariel Maintenance and Repair Manual.
NOTE: Ariel recommends the use of shipboard or armored cabling as opposed to wiring in conduit to minimize nuisance shutdowns due to wire
chafing and shorts. Cable in cable trays also facilitates maintenance access.

CAUTION: DO NOT drill holes in cylinders or other pressure containing components for any purpose. Epoxy-mounted clamps (to bare
metal) for wiring and tubing are a suitable alternative. See Ariel ER-89.10.

TABLE 1 Required Instrumentation Summary

INSTRUMENT SUPPLIER SETTING/REQUIREMENT

Frame Oil System (see ER-56.06)
Oil Pressure Packager
Start Permissive with Pre-lube Pump 30 psig (2.1 barg) for 2 minutes

Run Permissive 45 psig (3.1 barg) within 10 seconds of start

Alarm 50 psig (3.4 barg)

Shutdown 45 psig (3.1 barg)

Oil Filter Differential Ariel

JG:A:M:P:N:Q:R:J:H: E, KB100, JGK:T/2/4, KBE:K:T/2/4, Change at 10 psi (0.7 bar) or 4000 hours, whichever occurs first.
JGC:D:F/2

JGC:D:F/4/6, JGK:T/6, KBK:T/6, KBB:V:Z:U Change at 15 psi (1.0 bar) or 4000 hours, whichever occurs first.

Oil Temperature Packager

Minimum, to start up or to load See ER-56.06 for max. oil viscosity based on frame size.

Minimum, operating 150°F (66°C)

Maximum, shutdown 190°F (88°C)

Crankcase Level Packager 1/2 to 2/3 sight glass level

Low Level Shutdown 1/4 sight glass level

Main Bearing Temp. Ariel Standard on B:V:Z:U. Recommended, but optional on JG:A:R:J:H:E:K:T:C:D:F &
KBE:K:T.
Thrust Bearing Temp. Ariel Standard on B:V, optional on JGC:D:F:Z:U and KBZ:U.
Alarm +20°F (11°C) above normal not to exceed 220°F (104°C)

Shutdown +30°F (17°C) above normal not to exceed 230°F (110°C)

Differential Alarm 20°F (11°C)

Differential Shutdown 30°F (17°C)

Packing Case Temp. Ariel Optional

Alarm +20°F (11°C) above normal
INSTRUMENT SUPPLIER SETTING/REQUIREMENT

Shutdown +30°F (17°C) above normal

Packing Case Vent Packager Optional

Vent Flow Alarm 2 - 4 scfm (per throw)

Vent Flow Shutdown > 4 scfm (per throw)

Scrubber Liquid Level Packager

High Liquid Level Control

High Liquid Level Shutdown

Gas Conditions Packager

Inlet Temperature Indicator, each cylinder

Inlet Pressure Indicator, each stage

Discharge Pressure Indicator, each stage

Discharge Temperature Indicator, each cylinder, each nozzle on dual nozzle cylinders

High Discharge Temperature 10% above normala

Shutdown, each cylinder (Not to exceed the maximum temperatures below)

Lubricated Cylinders 350°F (177°C)

Non-Lube/PRC Cylinders 325°F (163°C)

Hydrogen Rich > 50% < 0.41 Specific Gravity 300°F (149°C)

Air Not to exceed autoignition temperature of cylinder lubricant at discharge pressure

Relief Valve Setting above normal operating pressure Up to 150: 15 psig to 2500: 10% to 3500: 8% to 5000: 6% Over 5000: As
(not to exceed MAWP) (1.0 barg) agreed
See ER-56.04.
Cyl. Rod Load Protection Packager
High Vibration Shutdown Packager As close to normal level as practical. See TABLE 3.
Over Speed Packager 10% over rated speed for shutdown
Dead Space Pressure Packager See Note #9. Required on KB100 ONLY.
Alarm 5 psi above cylinder suction pressure

Shutdown 10 psi above cylinder suction pressure

a. Example: Normal Discharge Temp. = 270°F; Shutdown Setting = 270 x 1.1 = 297°F.

Notes
1. Install the compressor frame low lube oil pressure shutdown set to stop the unit if oil pressure downstream of the filter falls below 45 psig (3.1 barg).
Compressor operation for only a few seconds without oil pressure causes major damage. Normal oil pressure is about 60 psig (4.1 barg) at full rated
speed and normal operating temperature. The low oil pressure shutdown must activate after oil pressure exceeds 45 psig (3.1 barg) at start-up. Ariel
provides a 1/4 inch tubing fitting to connect the low lube oil pressure shutdown and ties a tag to this connection before each compressor ships. Do not
operate the compressor for prolonged periods at less than 50 psig (3.4 barg) oil pressure.
2. Automated pre-lube systems require a start permissive to sense minimum required pressure/time at oil gallery inlet. See ER-56.06. Unit must shut down if
the system fails to achieve 45 psig (3.1 barg) oil pressure within 10 seconds after crankshaft starts to turn.
3. Mount overhead lube oil supply tanks high enough to provide oil flow to the level control at all ambient temperatures.
4. On multi-nozzle cylinders, Ariel strongly recommends a temperature device in both discharge nozzles.
5. Install the high lube oil inlet temperature shutdown at the filter inlet connection.
6. At a minimum, install one vibration shutdown for two and four throw frames and two for six throw frames. Mount vibration device near the top of the frame
with the sensitive axis parallel to the piston rod axis.
7. Install all safety shutdowns, controls, instrumentation, ignition systems, electrical devices, and high temperature piping (gas discharge and engine
exhaust) in accordance with good engineering practice and applicable codes for the area classification at the end user location. Ensure compatibility of all
systems for area classification.
8. If packing vent temperature is monitored, confirm alarm and shutdown set points through vent flow rates.
9. KB100 Dead Space Pressure Sensor Requirements: Add a pressure sensor to the ¼” NPT dead space pressure port on the 9-1/4 CE and 4-3/4 CE
cylinders (see FIGURE 1). The sensor indicates dead space over-pressurization, prevents compressor pin non-reversal damage, and provides an early
indication of piston ring leakage. Increased dead space pressure indicates piston ring leakage from either the high or low stage on the throw. Inspect
piston rings for damage or wear, and replace if needed. Use a 0.004-inch gauge pulsation damper (1/4” NPT) inline to average any dynamic pressure
before installing a suitable pressure sensor. The Alarm/SD should initiate when average dead space pressure exceeds average suction pressure by
TABLE 1 values. The alarm/SD value floats with average suction pressure. This pressure port is subject to high pulsation and temperature. If suction
 pressure is not available for the 4-3/4 CE cylinder, use the 9-3/4 CE cylinder discharge pressure and
account for pressure drop in the piping to determine second stage inlet.

FIGURE 1 Dead Space Pressure Port

Ariel Supplied End Devices

CAUTION: Any arc welding on the skid and/or associated equipment and piping can permanently damage solid-state electronic equipment.
Welding can cause immediate failure or reduce electronic equipment life and void the warranty. To protect electronic equipment prior to any
arc welding (including repair welding), disconnect all electrical connections including ground, and remove batteries, or completely remove
the electronic equipment from the compressor.

It is good practice to attach the welding ground clamp as close as possible to the area where the welding will occur and to use the lowest
practical welder output setting. Welding must not cause a current flow across any compressor bearing surface, including but not limited to
crankshaft and crosshead bearing surfaces.

Main Bearing, Thrust Bearing, and Packing Case Temperature Sensors

Thermocouples, Type J (Iron-Constantan) or K (Chromel-Alumel) - A thermocouple is two dissimilar conductors joined together at one end to form a
sensor that produces a thermoelectric voltage as an accurate function of temperature. Appropriate controls interpret the thermocouple voltage as
temperature.

Resistance Temperature Devices (RTD) - An RTD is a sensor that produces electrical

resistance as an accurate function of temperature. Appropriate controls interpret the
1. Element 1
electrical resistance as temperature. A typical measurement technique sends a small
2. White Wire
constant current through the sensor and measures voltage across the sensor with a digital
3. Red Wire
voltmeter to indicate resistance by a computer and wave-fitting equations.
4. Element 2
For main or thrust bearing temperature sensing, Ariel supplies dual element, six-wire, 100 5. Black Wire
Ohm (at 0°C) RTD’s. Dual element RTD’s allow rewiring instead of sensor replacement if 6. Green Wire
an element fails. Insulate unused wire ends from each other and conduit ground.

To simplify wiring, RTD's come with two green wires and one black for one element, and
two red wires and one white for the other. See FIGURE 2.
A Zone 1 environment may require the installation of proper, intrinsically safe or equivalent
protection to fulfill electrical requirements.
FIGURE 2 Typical Dual
Force Feed Lubrication System Monitoring Element RTD Wiring
Diagram
Ariel requires the control panel to shut down the unit if a lube distribution block stops
cycling during compressor operation. Set the shutdown to a maximum of 3 minutes. This is
a class B shutdown, defined as a shutdown unarmed until a short time (typically 2 minutes)
after the compressor starts. This allows divider blocks time to cycle the first time before the
shutdown activates.

Ariel requires all force feed lubrication monitoring devices to be grounded back to the control panel earth ground, and all unused wires to be individually
isolated so they cannot contact each other or external sources. Improper grounding and wiring can result in unreliable monitor operation, phantom
shutdowns, and premature device failure.
Ariel offers several lube system shutdown devices. See TABLE 2 for specifications on available types. For detailed information about each device, visit the
vendor literature section of www.arielcorp.com.

Shutdown Switch
The shutdown switch monitors divider block pin position and supplies a shutdown contact. If the divider block stops cycling for a given time, the switch sends
a shutdown signal to the control system.
For no flow shutdown devices, Normally Open (NO) refers to the switch state while the divider block cycles or the unit runs. An NO switch means when the
unit runs, the shutdown switch is open or non-failsafe; the control system cannot detect damaged devices or loose or cut wires at start-up and will never stop
the unit. A Normally Closed (NC) switch means when the unit runs, the shutdown switch is closed or failsafe; the control system will detect a loose or cut wire
and shutdown the unit.
Ariel recommends NC (failsafe) switches. However, when a NO (non-failsafe) switch is used, Ariel recommends testing shutdown circuits at least once a
month.

Proximity Switch
The proximity switch senses divider block piston position and changes switch state or pulses with every position change. This device must work with a PLC
or some other counter/timer device to produce a shutdown. Some devices open the switch when the pin is in and close when the pin is out. Others produce a
0.5 second pulse when the pin moves in and out. With pulses, the control system must sense switch cycling and stop the unit if a block stops cycling.
When using a proximity switch, a local cycle indicator is required for local monitoring of lube cycle times.

Ariel recommends a control system set to find the time between triggered cycles when the switch transitions from off to on. See FIGURE 3.
1. Shutdown Time with No Lubrication - Distribution block cycle times vary slightly from cycle to cycle; 12 seconds for one cycle, then 15, then 14 is
normal. The recommended shutdown time is double the design cycle time + 30 seconds, limited between 30 seconds and 3 minutes.
Shutdown Time = (2 x design cycle time + 30 seconds)
Find design cycle time on the compressor lube sheets or the compressor tag.
2. DE-BOUNCE and Latching Circuits - The device and control system scan time may necessitate de-bounce hardware and/or software. Some devices
include no built-in de-bounce circuits and can cause a fast control system to double or triple count. Other times, it may be necessary to latch input to
allow the control system to detect only the first transition from low to high. This becomes significant when displaying the cycle time for the operator to set
pump flow rates and when calculating total oil through the divider block.
3. Suggested Operator Displays
Divider Block Cycle Time - Set lube system pumps according to recommended divider block cycle times. A display of divider block cycle time in
seconds is helpful to adjust lube pumps as they wear out, or to set divider block cycle times at pump replacement.
Time Since Last Pulse - It is helpful to display the timer so the operator sees it actively timing.
Average Cycle Time - Cycle time varies a few seconds from cycle to cycle. It is sometimes helpful to display a cycle time averaged over 5 to 10 cycles.
Total Oil Consumed - Displays how much oil the lube system uses for accurate oil orders.
4. Sample Flow Diagram to Create Shutdown - FIGURE 3 shows one method to create a shutdown within the PLC from a cycling digital input.

FIGURE 3 Suggested Force Feed Lube System Proximity Switch Shutdown Logic Diagram

TABLE 2 Force Feed Lube System Monitors - Specifications

Specification Proximity Switch DNFT Programmable DNFT

Shutdown Signal NO YES YES
Proximity Signal YES YES YES
Local Data Storage NO NO Count Display
Infrared Port NO NO NO
Remote Mounting NO NO NO
Local Cycle Indicator Separate Indicator YES - LED YES - LCD & LED
De-bounce Included NO YES YES
Power N/A Battery: A-10807 Battery: A-10807
or 24 VDC or 24 VDC
Shutdown Time PLC 180 seconds Programmable
20 to 255 seconds
Area Classification CSA, IECEX, ATEX
 Specification Proximity Switch DNFT Programmable DNFT

CSA CSA 186200 (Canada): Ex d m IIC T5

CSA 186200 (US): Ex d m IIC T5, Class I, Zone 1, AEx d mb IIC T5 Gb
IECEX IECEx CSA 12.0020, Ex d mb IIC T5 Gb
ATEX II 2G SIRA 12ATEX1357, Ex d mb IIC T5 Gb
Temperature -40°F to +131°F (-40°C to +55°C)
Max. Switch Voltage 240 VDC
Max. Switch Current 10.4 mA
Max. Switch Power 2.5 VA

Vibration Protection (Packager Supplied)

Ariel requires sensors, such as a vibration switch or transmitter, to protect the equipment in the event of excessive vibration. Adjust alarm and shutdown
levels on site under normal running conditions. Below are typical vibration levels established from field experience:

TABLE 3 Typical Vibration Levels for Ariel Reciprocating Compressors, inch/sec (mm/s)

Package Components JG:A:M:P:N:Q:R:W, KB100 JGJ:H:E:K:T, KBE:K:T JGC:D:F:B:V:Z:U, KBB:V:Z:U

Skid <0.10 (<2.5) <0.15 (<3.8) <0.20 (<5.1)
Compressor Frame <0.20 (<5.1) <0.40 (<10) <0.50 (<13)
Compressor Cylinder <0.45 (<11) <0.80 (<20) <1.0 (<25)
Tandem Cylinder <0.70 (<18) <1.0 (<25) <1.0 (<25)

1. Ariel does not provide vibration limits for skid piping, bottles, or scrubbers.
2. Table does not apply to JGI - vertical non-balanced compressors.
3. These figures apply to balanced opposed reciprocating compressors. They are measured in terms of velocity, inches per second (mm/s), in zero to peak
values, band filtered from 10 to 250 Hz. The values are guidelines only. In general, if vibration levels fall below those in TABLE 3, stress levels are well
below equipment fatigue stress limit.
4. Analyze levels exceeding TABLE 3 values to determine the cause. A spectral vibration analysis should be performed by a qualified vibration specialist.

The following devices are acceptable for use on Ariel equipment.

Vibration Switch
Ariel requires installation of an inertial or electronic vibration switch with the sensitive axis in the piston rod direction. A minimum of 2 switches are
recommended for six throw machines. Switches are not required if transducers are utilized.

Velocity Transducers
For frames over 500 HP, Ariel recommends velocity transducers (or accelerometer transducers integrated to a velocity measure) from a 10-250 Hz
bandwidth, measured in peak or RMS converted to peak levels.
Mount velocity transducers perpendicular to the crankshaft at the crankshaft centerline elevation. A single transducer on the drive end is adequate on 2-
throw and 4-throw machines. Six-throw frames require one transducer on the drive end and one on the auxiliary end. Many Ariel frames now have machined
bosses for easy and solid connection. TABLE 3 guidelines can be applied to these readings. The packager may set these levels as initial alarms in the shop,
but must reduce them to more conservative protection levels after achieving normal operation.

Load changes from pneumatic clearance pockets or HE unloader actuation may cause intermittent high vibration levels that can cause nuisance shutdowns.
If this is problematic, a 1-second delay to ensure the vibration is not a transient condition is acceptable. Other more complicated methods in control logic can
prevent these nuisance shutdowns as well.

Accelerometer Transducers
Acceleration measurement on the frame or crosshead guides is sometimes a preferred method and acceptable as a secondary method of protection.
Typically, acceleration is measured with a high sample rate over a wide bandwidth to quantify impact levels for protection. The many factors associated with
this measurement (sensor resonance, sample rate, mounting, structure resonance), prohibit Ariel from providing predetermined amplitude limits. Set
shutdown and alarms for these devices to a practical level above normal after normal operation is achieved. Given the variability of acceleration responses,
shutdown and alarms (as a percentage of normal operation) may vary with application. These measurements can also be sensitive to unloader and pocket
activation.

Impact Sensors
Use of crosshead guide impact sensors or accelerometers is optional. Impact sensors monitor and count peak G levels over a set threshold for a certain
number of revolutions, and report the count to the panel, usually in a 4-20mA current loop. They are typically mounted in the vertical direction on the
crosshead guide or in the horizontal direction on the frame and are acceptable as a second level of protection.
On high speed separable compressors, crosshead guides have a fairly high impact response in the vertical direction due to normal rod reversals. Sometimes
a normal machine response can saturate impact sensor electronics and cause nuisance alarms and shutdowns. Mount impact sensors on a machined
surface. If a mounting location is not already available, these sensors can be mounted on the lifting eye machined surface. If a different location is preferred,
drill, tap, and spot face the mounting hole. It is critical to drill the hole straight so the sensor sits flat on the machine.
Mounting sensors on the frame in the horizontal direction at centerline elevation is also acceptable as a second level of protection. Impact responses from
looseness and debris transmit to the sensor effectively in this location. For frame mounting, use the machined frame bosses if possible. One impact sensor
per each pair of throws or in between throws offers adequate protection. Drill, tap, and spot face mounting hole. It is critical to drill the hole straight so the
sensor sits flat on the machine.
Impact sensors must be selected based on the intended operating speed of the compressor. Impact sensors require field tuning with a calibration
tool. Consult manufacturer instructions for adjustment. Typical settings: time the reset level to capture approximately 16 revolutions at normal operating
speed. Set the threshold to 1.25 to 3 times the normal baseline level depending on how unit load changes affect sensor response.

Document contents are proprietary and confidential. They are the property of Ariel Corporation and may not be disclosed, reproduced, or used for manufacture in part or in
whole without written permission from Ariel Corporation.

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